Iterative Standard Strategy for Non-Linear Optimization in Melting Furnace Charge Calculations

This paper describes an approach to furnace charge calculation for melting processes, achieve a specified target melt in crucible or induction furnaces with minimum material cost. There has been challenge the problem regarding loss, contaminations, and unwanted physiochemical reactions during process. Those put high degree of complexity, non-linearity, uncertainty on calculations. The current study presents model that takes three important complexities into account, including non-homogeneous element loss melting, non-metal contaminations scraps/charges, correction possible initial furnace. was based mass balance chemical elements along optimization weights materials. It re-arrangement non-linear formulations iterative standard linear-programming framework. To evaluate performance model, industrial-scale test case introduced. find optimum combination materials brass alloy C47940 10-ton Eight different types were introduced amounts non-metallic ratios each. Also, 7-ton out-of-range considered be corrected. matrix coefficients build according numerical algorithm model. Optimizations successfully performed 3–5 iterations Excel solver. For case, calculations showed fractions burdens predicted give 9649 kg ~ 262 total loss. An optimality analysis conducted solution reached revealed convergent fast performance. feature provides backbone reliable operations which is significant benefit industrial automation.